00 - General, Technical data

30 - Clutch
34 - Manual Transmission - Controls, Housing
35 - Manual Transmission - Gears, Shafts
39 - Final drive, Differential


- General, Technical data
Transmission identification
Code letters, transmission allocation, ratios, capacities
Transmission Iayout
CaIcuIating overaII ratio (i)
GeneraI repair instructions
00-1




Transmission identification
The manual transmission 02G is installed in
the EuroVan as a 5-speed transmission in
conjunction with the 5-cylinder engine.
Applications Page 00-3 .


Location on transmission
Code letters and date of manufacture (arrow
1)
Manual transmission 02G (arrow 2)


ManuaI transmission 02G (arrow 2)

00-2





Code Ietters and date of manufacture of
transmission (arrow 1)
ExampIe: AFK 24 08 5
I I I I
I I I I
Code
letters
Day Month Year (1995)
of
manufacture
Additional data depends on manufacture.
Note:
The transmission code letters are also shown on
the vehicle identification plates.

00-3



Code Ietters, transmission aIIocation, ratios, capacities
ManuaI transmission 5-speed 02G
Engine code AFK
Manufactured from
to
08.95


AppIication Model EuroVan 1996
Engine 2.5 L - 75 kW
(100 hp)
Turbo Diesel

Ratio: Z2 : Z1 Final drive 82 : 21 = 3.905
1st gear 43 : 11 = 3.909
2nd gear 36 : 17 = 2.118
3rd gear 35 : 26 = 1.346
5th gear 35 : 48 = 0.729
6th gear -
Reverse gear 37 : 23 x 23 : 10 =3.700
Speedometer drive 13 : 22 = 0.591


00-4



Engine code AFK
Capacity 2.3 litres
Specification Gear oil G50 SAE 75W90 (synthetic oil)
CIutch controI hydraulic
CIutch pIate diameter 219 mm
Drive shaft fIange diameter 108 mm
iOveraII ratio in top gear 2.847

00-5





Transmission
Iayout
Designation
1 - Engine
2 - CIutch
3 - Transmission
4 - Input shaft
5 - Output
shaft/pinion
shaft
6 - DifferentiaI
Arrows point in
direction of travel

00-6




Gears
I -

1st gear
II -

2nd gear
III -

3rd gear
IV -

4th gear
V -

5th gear
R -

Reverse gear
A -

Final drive
T -

Speedometer
drive
Arrows point in
direction of travel
00-7




CaIcuIating overaII ratio (i)
ExampIe:

5th gear Final drive
Drive gear ZG1 = 48 ZA1 = 21
Driven gear ZG2 = 35 ZA2 = 82

i = Z2 : Z1 1)
iG = Gear ratio = ZG2 : ZG1 = 35 : 48 = 0.729
iA = Axle ratio = ZA2 : ZA1 = 82 : 21 = 3.905
ioverall ratio = Total ratio
ioverall ratio = iG x iA = 0.729 x 3.905 = 2.847

1)
Z1 = No. of teeth drive gear, Z2 = No. of teeth
driven gear
00-8




GeneraI repair instructions
To ensure perfect and successful transmission
repairs, the greatest care and cleanliness as
well as the use of good and proper tools is
essential. Obviously, the basic rules for safety
are also applicable during all repair work.
A number of generally valid instructions
applicable for the various repair procedures -
which were previously repeated a number of
times at numerous places in the Repair Manual
- are summarized here. They apply to this
Repair Manual.
Transmission


When installing ensure that the dowel
sleeves between the engine and
transmission are correctly located.



When changing a transmission fill with gear
oil to the lower edge of the filler hole.



Capacities and specifications Page 00-3 .


00-9



Gaskets, seaIing rings


Thoroughly clean joint surfaces and apply
sealant AMV 188 200 03.



Apply sealant uniformly but not too thick.



Always replace "O-rings".



Radial shaft oil seals -

Before instaIIing:


- Lightly oil outer edge, fill space between
sealing lips -arrow- with grease.
After instaIIation:
- Check transmission oil and top-up if
necessary
Specification Page 00-3 .
Locking devices

Always replace circlips.

Do not overstretch circlips.

Circlips must locate properly in the groove.




Replace spring pins. Installation position:
Slot longitudinal to line of force.


00-10



BoIts and nuts


Tighten and loosen bolts and nuts for
securing covers and housings in a diagonal
sequence.



Especially delicate parts, such as clutch
pressure plates, must not be distorted.
Loosen and tighten nuts and bolts in stages
in a diagonal sequence.


Tightening torques as specified are for
unoiled bolts and nuts.



Always replace self-locking bolts and nuts.

Bearings


Install needle bearings with lettered side
(thicker metal) towards fitting tool.



Lubricate all transmission bearings with
gear oil before installing. Lubricate with
special care when measuring turning torque.



Tapered roller bearings installed on one
shaft must be replaced as a set. Use
bearings from the same manufacturer if
possible!



Heat inner tapered roller bearing races to
approx. 100 C before pressing on.



Do not interchange outer and inner races of
bearings of the same size; bearings are
paired.


00-11



Shims


Measure shims at several points with a
micrometer. Tolerance variations make it
possible to find the exact shim thickness
required.



Check for burrs and damage.



Only install perfect shims.

Synchronizer rings


Do not interchange. When reusing always
match to same gear.



Check for wear and replace if necessary.



Coat with gear oil before installing.

Gears


Before installing clean and heat on a hot
plate to approx. 100 C (212 F).



Temperature can be checked with
temperature tester VAG 1558 or equivalent.

30-1





CIutch controI,
servicing
I - AssembIy
overview -
pedaI cIuster
Page 30-2
II - AssembIy
overview -
hydrauIics
and cIutch
reIease
Page 30-6
Notes:

Disconnect
battery ground
strap.

Obtain radio
code for
vehicles with
coded radio.

Lubricate all
bearings and
contact
surfaces with
MoS2 grease.
Before working
on the pedal
cluster remove
the following
components:
Driver's side storage
compartment
Repair Manual, Body
Interior, Repair Group
70,
Steering column trim
Repair Manual,
Suspension, Wheels,
Brakes, Steering m.y.
1992-1996, Repair
Group 48
Relay plate (releasing
from mounting)
Repair Manual,
Electrical Equipment,
Repair Group 97, wiring


30-2





PedaI cIuster -
assembIy overview
1 - CIutch pedaI

Removing and
installing
Page 30-5
2 - Locking cIip
3 - Master cyIinder
4 - Combi-boIt, 20
Nm (18 ft Ib)

For master
cylinder to
mounting
bracket
5 - Washer
6 - Locking cIip
7 - Bushing
8 - Over-center
spring

Removing and
installing
Page 30-11


30-3





9 - Line union nut,
20 Nm (18 ft Ib)
10 - Hex boIt, 25 Nm
(18 ft Ib)
11 - Pressure Iine
12 - SuppIy hose
13 - Mounting pIate

Need not be
disassembled
to remove
pedal cluster

Seal to
bulkhead with
AKD 497 010
04 R 10
14 - Hex boIt, 25 Nm
(18 ft Ib)
15 - Brake servo
stud
16 - Mounting
bracket

Before
removing
unbolt steering
column and lay
to side
Repair Mnaual,
Suspension, Wheels,
Brakes, Steering m.y.
1992-1996, Repair
Group 48

30-4





17 - Pivot pin

For clutch and
brake pedal

Knock out with
drift
18 - SeIf-Iocking hex
nut, 25 Nm (18 ft
Ib)

Always replace

For mounting
bracket and
brake servo to
mounting plate
19 - Pivot pin

For master
cylinder
operating rod
20 - Locking cIip


30-5




CIutch pedaI, removing and instaIIing
Removing

- Separate clutch pedal from master cylinder
Page 30-2 .


- Remove over-center spring Page 30-11 .


- Remove clutch pedal locking clip from pivot
pin.


- Drive pivot pin out to right until clutch pedal
can be pulled off.


- Remove clutch pedal.

InstaIIing
Installation is performed in the reverse
sequence.

30-6





HydrauIic cIutch
reIease - assembIy,
overview
1 - Brake fIuid
reservoir
2 - SuppIy hose
3 - Mounting pIate
4 - Master cyIinder
5 - CIutch pedaI

Removing and
installing
Page 30-5
6 - Pivot pin

For master
cylinder
operating rod
7 - Locking cIip
8 - Securing boIt,
20 Nm (18 ft Ib)

For master
cylinder to
mounting
bracket


30-7





9 - Line union nut,
20 Nm (18 ft Ib)
10 - Pressure Iine
11 - Grommet
12 - Dust cap
13 - BIeed
vaIve/master
cyIinder

Bleeding clutch
system Page
30-12
14 - Intermediate
piece
15 - Line union nut,
20 Nm (18 ft Ib)
16 - Pressure Iine
17 - O-ring

Always replace

Pull onto
line/hose
connection

Coat with brake
fluid before
installing


30-8





18 - CIip

Removing
Fig. 1

Installing: press
in by hand
19 - Hex boIt, 25 Nm
(18 ft Ib)
20 - Connecting
piece
21 - Hose bracket

Secure to left-
hand
transmission
support
22 - VaIve unit, 5 Nm
(44 in. Ib)
23 - Transmission
24 - Hose bracket

Secured to
mounting plate
25 - Hose assembIy
26 - Pressure Iine
27 - Line union nut,
20 Nm (18 ft Ib)


30-9





28 - SIave cyIinder
29 - ReIease bearing

Pry out with a
screwdriver
30 - Hex boIt, 12 Nm
(9 ft Ib)

Qty. 2
31 - Rubber cap

Qty. 3

Install on slave
cylinder flange
32 - LIne
33 - BIeed
vaIve/master
cyIinder

Bleeding clutch
system Page
30-12
34 - Dust cap
35 - O-ring

Always replace
36 - Union boIt


30-10





Fig. 1 CIip, removing
- Guide screwdriver between clip and
connecting piece, if necessary turn
connecting piece first so that flattened
section of connecting piece that is in area of
clip is pointing forward.
- Carefully pry clip out and remove.


30-11




Over-center spring, removing and
instaIIing
Removing

- Remove carpet in area of over-center spring.


- Pry securing clip off with a screwdriver and
remove washer.



- Tension over-center spring with clutch pedal
and install retaining clamp 3113A from above.
CAUTlON!
Do not press retaining clamp on from below;
there is a danger that the over-center spring
may jump out of the retaining clamp during
installation.
- Move clutch pedal onto stop.
- Remove over-center spring together with
retaining clamp 3113A.



- Remove over-center spring from retaining
clamp and install.
InstaIIing
Installation is performed in the reverse
sequence.

30-12




CIutch system, bIeeding
Bleed clutch system using the brake filling and
bleeding appliance VAG1238 B and bleed hose
VAG 1238 B/3 or use Fluid Evacuator EZ1 or
equivalent.

- Remove insulation tray below
engine/transmission.


- Connect pressure hose -C- to brake fluid
reservoir.



- Step 1: Connect bleed hose -A- to bleed valve -
B- in engine compartment and open bleed
valve.
- Switch on bleeder unit.



- Step 2: Connect bleed hose -A- to bleed valve -
arrow- below transmission and open bleed
valve.
- Switch on bleeder unit.
- Step 3: Repeat bleed sequence at bleed valve -
B- in engine compartment, illustration N30-
0144.
- Depress clutch pedal several times after
completion of bleeding process.

30-13





CIutch,
servicing
(Transmission
installed)
Notes:

Replace clutch
plates and pressure
plates having
damaged or loose
rivets

Ensure correct
clutch plate and
pressure plate is
selected from parts
list
1 - FIywheeI

Ensure
centering pins
are a tight fit

Contact
surface for
clutch lining
must be free of
grooves, oil
and grease

Removing and
installing
Repair Manual,
Engine Mechanical,
Repair Group13

30-14





2 - CIutch pIate

Diameter
page 00-3

Installation
position:
Shorter hub
end (arrow)
points toward
pressure plate

Centering
Fig. 1

Lightly grease
splines
Note:
Clean input shaft
splines and, on used
clutch plates, the hub
splines. Remove
corrosion and apply
only a very thin coating
of grease Part No: G
000 100 to the input
shaft splines. Then
move the clutch plate
back and forth on the
input shaft until the hub
moves freely on the
shaft. Excess grease
must be removed.

30-15





3 - Pressure pIate

Removing and
installing Fig.
1

Check ends of
diaphragm
spring Fig. 2
Note:
Pressure plates are
protected against
corrosion and greased.
Only the contact
surface may be
cleaned, otherwise the
service life of the clutch
will be considerably
reduced.
4 - BoIt, 13 Nm

Loosen and
tighten
gradually and
diagonally


30-16





Fig. 1 CIutch pIate, centering; pressure
pIate, removing and instaIIing
- Loosen and tighten bolts gradually and
diagonally.
- Reverse position of retainer 3067 when
removing.
Note:
The pressure plate contact surface and the
clutch plate lining must make full contact with
the flywheel. Tighten securing bolts diagonally
and evenly so as to prevent damage to the
pressure plate centering hole and the flywheel
centering pins.


Fig. 2 Diaphragm spring, checking ends
(arrows)

Wear up to half the thickness of the
diaphragm spring is permitted.

34-1





Gear seIector
mechanism,
servicing
InstaIIation position
of gear seIector
mechanism
A - Gear
seIector rod
B - Gate seIector
rod
Double-headed arrow -
A- Gear selection
movement
Double-headed arrow -
B- Gate selection
movement
1 - Gear seIector
Iever
2 - SwiveI head
with seIector
rod


34-2





I - Removing
and instaIIing
gear shift
housing
Page 34-3
II - Removing
and instaIIing
seIector rods
and gate rod
Page 34-6
III - Removing
and instaIIing
gear Iever
Page 34-15
Removing and installing
selector mechanism
Page 34-19
Notes:

Before working
on the selector
mechanism,
disconnect the
battery ground
strap in the
engine
compartment.

Note radio
code on
vehicles with
coded radio.

Lubricate all
mountings and
contact
surfaces with
MoS2 grease.

Adjusting
selector cables
Page34-23


34-3





Gear shift housing,
removing and
instaIIing
1 - Gear shift knob

Thread on and
off together
with boot (item
2 )

When
threading on
hold boot in
position
2 - Boot

To remove,
unclip from
frame (item 4 )

Remove and
install together
with gear shift
knob (item 1 )

After installing
clip into frame
(item 4 )

Installation
position Page
34-22 ,
illustration V34-
2980


34-4





3 - Boot w/frame

Remove and
install together
with frame
(item 4 )
Page 34-19
and Page 34-
22

Clip and unclip
into frame (item
4 ) Page 34-
22 , Fig. 34-
2978

Installation
position:
Inscription
""VORN" (front)
points in
direction of
travel
4 - Frame

Remove and
install together
with boot (item
3 ) Page 34-
19 and Page
34-22

Installation
position:
Inscription
"VORN" (front)
-arrow- points
in direction of
travel Page
34-22 ,
illustrationV34-
2978


34-5





5 - Gasket

When installing
place on edge
of floor plate

Installation
position: Arrow
type markings
point in
direction of
travel, lip
toward floor
plate
6 - FIoor pIate
7 - Gear shift
housing
8 - Hex boIt, 5 Nm
(44 in. Ib)


34-6





SeIector rods and
gate rod, removing
and instaIIing
1 - Gate rod

Remove from
transmission
together with
mounting
bracket (item
15 )

Removing from
gearshift
bracket Page
34-20
2 - Bushing
3 - Rear seIector
rod

Remove from
gear shift and
relay lever
Page 34-20
4 - Bushing

Pry out with
screwdriver

Installing Fig.
1
5 - ReIay Iever

Installation
position Fig.
9


34-7





6 - Front seIector
rod

Lever off and
press into gear
selector lever
(item 12 )
7 - SeIf-Iocking hex
nut, 25 Nm (18 ft
Ib)
8 - SeIf-Iocking hex
boIt, 9 Nm (7 ft
Ib)
9 - SwiveI head
10 - Bushing

For front
selector rod

Press into gear
selector lever
Fig. 8
11 - SeIf-Iocking hex
nut, 25 Nm (18 ft
Ib)
12 - Gear seIector
Iever

Install so that
master spline
aligns with
selector shaft


34-8





13 - SeIector shaft
14 - Hex boIt, 20 Nm
(15 ft Ib)

For mounting
bracket to
transmission
15 - Mounting
bracket

Removing from
gate rod Fig.
2

Pressing on
Fig. 3
16 - Bushing

Removing
Fig. 4

Installing Fig.
5
17 - Reverse gear
cabIe

Transmission
side: engage in
reverse gear
locking unit

Secure to gate
rod (item 1 )

Engage onto
gear shift
housing and
hook onto lever
Page 34-15


34-9





18 - Bearing baII

Mounts gate
rod in swivel
head

Pressing off
Fig. 6

Pressing on
Fig. 7
19 - Bearing baII

Mounts gate
rod in mounting
bracket

Pressing off
Fig. 6

Pressing on
Fig. 7


34-10





Fig. 1 Mounting bushings, pressing in
Installation position:
Press in from smaller shoulder side of center
mounting.


Fig. 2 Gate rod mounting bracket,
removing
- Remove in direction of arrow.


34-11





Fig. 3 Gate rod mounting bracket,
pressing on



Fig. 4 Bushing, pressing out of
mounting bracket


34-12





Fig. 5 Bushing, pressing into mounting
bracket
- Coat bushing lightly with MoS2 grease and
carefully press in.



Fig. 6 BaII, pressing off gate rod
A - Separating device 5 ... 60 mm, e.g. Kukko
17/0
B - Driver, 6 mm diameter

34-13





Fig. 7 BaII, pressing on gate rod



Fig. 8 Bushing, pressing into
transmission seIector Iever


34-14





Fig. 9 ReIay Iever, instaIIation position
Dimension "a" = 78 mm - points to left-hand
side of vehicle
Dimension "b" = 80 mm - points to right-hand
side of vehicle
The thicker shoulder -arrow- points downward.

34-15





Gear shift
mechanism,
removing and
instaIIing
1 - Gear shift
housing

Disassembling
and
assembling to
floor plate
Page 34-20
2 - Bushing

Pry out with a
screwdriver
before
removing
rubber
mounting (item
3 )
3 - Rubber
mounting

Pry out with a
screwdriver
after removing
bushing
4 - Grub screw, 4
Nm (35 in. Ib)
5 - Stop

Installation
position Page
34-23
6 - Spring


34-16





7 - Gear shift
bracket

Remove with
gear shift

First remove
following
components:
rear selector
rod (item 15 ),
gate rod (item
20 )
8 - Hex boIt
9 - CIamp

Loosen to
adjust gear
selector
mechanism
and to remove
selector and
gate rods
10 - SeIf-Iocking hex
nut, 20 Nm (15 ft
Ib)
11 - Guide sIeeve

Two part


34-17





12 - Gear shift

Top section
angled
rearward
13 - Bushing
14 - SpeciaI boIt
15 - Rear seIector
rod
16 - Washer
17 - Bushing
18 - Bushing
19 - Spring pin

Knock out with
drift
20 - Gate rod

Removing and
installing to
transmission
Page 34-19
and Page 34-
21


34-18





21 - Bushing
22 - Rubber washer
23 - Reverse gear
cabIe

Hook into lever
(item 24 )
24 - Lever

Changes
downward
motion -arrow-
of gear shift to
cable
movement
25 - PuII rod

Mounted on
bushing (item
18 )
26 - SeIf-Iocking hex
nut
27 - RoIIer
28 - CircIip
29 - Mounting pin
30 - CircIip
31 - Washer
32 - Bushing


34-19




SeIector mechanism, removing and
instaIIing
Removing

- Unclip boot from frame, unscrew and remove
from gearshift together with gear knob Page
34-3 , items 1 and 2 .



- Release frame -a- from gearshift housing -b-
by prying upward in front and rear areas -
arrows-.
Note:
Only remove and install boot and frame together.
- Remove seal from floor plate.



- Unbolt swivel head -arrow 1-.
- Pry front selector rod off transmission selector
lever -arrow 2-.
- Unbolt mounting bracket with gate rod -arrow
3-.
- Unclip reverse gear lock cable -arrow 4- from
reverse gear locking unit.


34-20




- Remove rear selector rod from relay lever.


- Remove rear selector rod from selector lever.



- After loosening the clamp -arrow- pull gate rod
forward, off gearshift bracket.
- Remove gearshift housing from floor plate.
- Press gear shift bracket together with gear
shift forward, so as to guide around fuel tank
and then remove downward.
- Guide gate rod with mounting bracket, relay
lever and front selector rod out rearward.


34-21



InstaIIing
Install in reverse order.

- Guide gear shift housing with gear shift
bracket and gear shifter into position from
below and secure.


- Guide gate rod into gearshift bracket and
slide onto guide pin. First install clamp (
Page 34-20 , illustration V34-2291, arrow).

Note:
Ensure freedom of movement at gate
rod/gearshift bracket joint, so that the selector
mechanism can be adjusted as described on
Page Page 34-23 .

- Hook rear selector rod into relay lever, right
illustration N34-0391, Page 34-14 .


- Adjust selector mechanism Page 34-23 .


34-22





- Engage lugs -arrow 1- around circumference
of boot into frame.
- Place seal around edge of floor plate.
- Place frame mounting tubes on gearshift
housing securing screws -arrow 4- and then
press, first front and then rear, fully home.
Inscription "VORN" (front) -arrow 2- points in
direction of travel
- Engage frame locking devices -arrow 3- by
pressing into gearshift housing cut-outs
Page 34-19 , illustration V34-2979.
- Thread on gearshift knob together with boot,
holding boot in position.
- Clip boot into frame.



One lug -arrow- on inside of boot is applied on
front (direction of travel).

34-23




Gear seIector mechanism, adjusting
Notes:
The following points are essential to ensure
correct selector adjustment:


Perfect operation of selector mechanism,
operating and relay elements.



Light selector mechanism operation.



Transmission, clutch and clutch operating
mechanisms must be in perfect condition.


- Place transmission in neutral position.


- Remove gear shift knob, boot, and boot frame
Page 34-19 .



- Loosen nut -arrow-.

The gate rod/gearshift bracket connection
must be free to move.
Note:
Check whether contact surfaces on selector lever
and gearshift housing stops are aligned parallel
to one another. Adjust if necessary.


- Align stop so that grub screw -A- locates in
gearshift depression -arrow-.


34-24





- Install gear shift jig until it sits on stop and
lock by tightening knurled wheel -arrow-.
- Align gate rod free of stress (transmission in
neutral) and tighten nut to 20 Nm (15 ft lb).
Page 34-23 , illustration V34-2291, arrow.
- Pull gear lever towards seat, loosen knurled
nut and remove jig.
FunctionaI check

The gear shift lever must rest in the 3rd/4th
gear plane with the transmission in neutral.
The lower area of the gearshift must be
vertical.
- Operate clutch.
- Select all gears several times. Pay particular
attention to operation of reverse gear catch.
Should a gear fail to engage smoothly after
repeated selection then continue as follows:
- Engage 1st gear.
- Remove play in selector mechanism by
carefully moving gearshift to the left.


34-25






The distance between gearshift stop and
gearshift housing must be approx. 2 mm
(dimension "a").
- Repeat adjustment sequence if necessary.
Reinstate dimension "a" with 1st gear
engaged if necessary.
- Install gear shift knob and covering Page
34-22 .

34-26




Transmission, removing and
instaIIing
Removing

- Switch ignition off and disconnect battery
strap (in engine compartment and if
equipped, under drivers side).


Repair Manual, Electrical Equipment, Repair
Group 27
Note:
Obtain radio code for vehicles with coded radio .

- Remove radiator grille with trim frame.


Repair Manual, Body Exterior, Repair Group
66


- Remove charge air cooler from lock carrier -
arrows- if equipped.
- Fold radiator and lock carrier out forward.
Repair Manual, Body Exterior, Repair Group
66

34-27





- Install support frames 3250 with vehicle in
unloaded condition to both sides before the
vehicle is raised.
Note:
Support frames 3250 allow removal of left-
hand drive shaft (illustration) and left and
right-hand shock absorber/stabilizer bar
coupling link.
InstaIIation position:
Support frame bearing surface -arrow A- must
be located below the upper control arm -1-.
The V-shaped opening -arrow B- bears on the
assembly carrier -2-.
Note:


Relieve torsion bar tension with special tool
3257 if necessary. First measure thread length
(arrow).
Repair Manual, Suspension, Wheels,
Brakes, Steering m.y. 1992-1996, Repair
Group 40

34-28





- With vehicle standing on wheels loosen left
and right-hand drive shaft/wheel hub bolt
and left and right-hand wheel bolts.
- Raise vehicle.
- Remove noise insulation tray below
engine/transmission..
Remove left and right-hand drive shafts as
follows:
- Remove bolt for left-hand shock
absorber/stabilizer bar coupling rod.
- Compress left-hand shock absorber
completely.
- Disconnect drive shaft at flange.
- Remove wheel.



- Separate lower wheel bearing housing ball
joint bolted connection. Support ball joint
when separating
- Remove drive shaft.


34-29





- Unbolt flange shaft mounting -A- from
bracket -B- -arrow-.
- Pull right-hand flange shaft -C- out from stub
shaft -D-.
- Remove battery ground strap from
transmission and mounting bracket.
- Remove all electrical connections from
transmission and starter motor.
Electrical system, Repair Group Gr. 27
- Unscrew speedometer drive shaft cable or
remove sensor connector and speedometer
sensor.
- If so attached, unfasten electrical wiring from
coolant hoses.



- Unfasten coolant lines at starter motor -
arrows- (from expansion tank to water
pump).
- Remove wiring harness from lines.
- Remove starter.
Repair Manual, Electrical Equipment, Repair
Group 27

34-30




- Remove front exhaust stop plate.


Repair Manual, Engine Mechanical, Repair
Group 26

- Separate front exhaust pipe at catalyst.


Repair Manual, Engine Mechanical, Repair
Group 26


- Remove transverse support after removing
bolts on selector mounting bracket -A- and bolt
on left-hand transmission support -B-.



Remove selector mechanism from transmission
as follows:
- Remove back-up light switch.
- Remove swivel head -arrow 1-.
- Pry front selector rod off transmission selector
lever -arrow 2-.
- Unbolt mounting bracket with gate rod -arrow
3-.
- Unclip reverse gear lock cable -arrow 4- from
transmission.
- Tie-up selector and gate rods.


34-31




- Remove clutch mechanism line from
transmission, release from transmission
support retainer and tie-up.


- Remove auxiliary heater line, if necessary.



- Remove pendulum support after removing
bolts arrows -A- and -B- by pushing up lightly
on rear of transmission restriction -arrow C-.
- Remove retaining plate for electrical
connectors from crankcase.



- Bolt engine support to block.


34-32





- Attach auxiliary support 3184/1 for removal
device 3184 into cross panel -arrows-.



- Install removal device 3184 into auxiliary
support 3184/1 and into subframe -A-.
Screw spindle -C- into hole on engine
mounting.
- Align removal device so that slide -B- is
resting against right-hand tube -arrow-.
- Secure removal device to subframe -A- and
to auxiliary support 3184/1 by tightening
angle plates.
- Relieve subframe loading by raising
engine/transmission by means of spindle -C-
.


34-33





- Remove engine/transmission connecting
bolts -arrows- except for bolt -arrow a-. Also
remove flywheel small cover plate.



- Remove engine/transmission hex socket-
head bolt -arrow-.
1

34-34





- Support transmission, left, with transmission
jack VAG 1383 A.
A - Trolley jack insert
- Unbolt left-hand transmission support -
arrows- on transmission.
- Lower engine using removal device spindle.
- Carefully rock engine/transmission
alternately forward and then lower until V-
belt pulley almost contacts longitudinal
member.
Note:
Do not damage coolant system hoses and
lines on cross member when rocking
engine/transmission assembly forward.

34-35




- Assemble transmission jack VAG 1383A with
transmission support 3282, adjustment plate
3282/23 (for "02G" transmission) and support
elements as follows:


- Place adjustment plate 3282/23 on
transmission support 3282. (Adjustment plate
only fits in one position).


- Align arms of transmission support according
to holes in adjustment plate.



- Bolt on support elements -A-, as illustrated on
adjustment plate.



- Place transmission jack with transmission
support under vehicle, arrow symbol -B- (
Illustration N34-0363) on adjustment plate
points to front of vehicle.
- Align adjustment plate parallel to transmission
and lock safety supports on transmission.
- Remove lower engine/transmission securing
bolts ( Page 34-33 arrow -A- on illustration
N34-0360).


34-36




- Press transmission off engine and remove
cover plate from between
engine/transmission.


- Carefully lower transmission and swing out.


- Constantly correct transmission position via
transmission jack spindles. Ensure there is
sufficient clearance to assembly carrier and
removal device 3184.

Note:
If the vehicle is to be moved with the removal
device fitted then the following must be
observed:


Screw spindle in onto stop, to lift or lower
the engine/transmission.



Exercise extreme care in the vicinity of a
hoist.


34-37



Transmission, transporting
Special tool 3336 may be used to transport the
transmission and also when setting up
transmission mount 3282.


- Bolt transmission lifting device 3336 to clutch
housing.



- Set support arm on sliding piece with locking
pin (arrow).
No. of holes visible = 7
- Remove transmission with workshop crane
and transmission lifting device 3336.


34-38



InstaIIing
Install in reverse order.
Note:


Determine transmission mounting parts via
parts catalog.



Check whether dowel sleeves for aligning
engine/transmission are installed in cylinder
block, install if necessary.



When replacing transmission ensure that
intermediate plate is correctly positioned.



When replacing transmission, transfer gear
selector lever to new assembly.



Clean input shaft splines and lightly grease
with G000 100 grease.


34-39




- Alternately swing in and raise
engine/transmission assembly.

Install engine/transmission mountings stress-free,
as follows:


- Before installing bolts to secure left-hand
mounting bracket to body ensure that engine
mounting pin and removal device spindle -
arrow- are in line.



- Use transmission support VAG 1383 A to
support transmission when guiding
transmission mounting bracket.
A - Trolley jack insert
- Tighten rear transmission mounting to torque
setting.
- Tighten pendulum support to torque.
CAUTlON!
Do not remove removal device 3184 until the
bolts securing the left-hand mounting bracket
have been securely tightened.

34-40




- Install front exhaust pipe to catalyst


Repair Manual, Engine Mechanical, Repair
Group 26, Removing and installing parts of
exhaust system.

- Always replace seal between flange shaft
and drive shaft, but first remove protective foil
before bolting drive shafts to flanges.


Repair Manual, Suspension, Wheels, Brakes,
Steering m.y. 1992-1996, Repair Group 40,
Servicing drive shaft

- Install starter/wiring.


Repair Manual, Electrical Equipment, Repair
Group 27

- Check transmission oil Page 34-44 .


- Adjust gear change mechanism Page 34-
23 .


34-41



Tightening torques


Transmission to Engine
Pos. BoIt Qty. Nm (ft Ib)
11) M 12 x 70 2 80 (59)
2 M 12 x 70 1 80 (59)
3 M 12 x 60 1 80 (59)
4 M 12 x 100 1 80 (59)
5 M 12 x 130 1 80 (59)
6 M 8 x 45 1 25 (18)
72) M 8 x 45 1 25 (18)
1)
Additionally for flywheel cover plate
2)
Tighten from engine side
Positions A & B = Dowel sleeves

34-42





Front left transmission mounting
Bolts -A- 50 Nm (37 ft lb) + 90
Bolt -B- 30 Nm (22 ft lb)
Bolts -C- 30 Nm (22 ft lb)



Rear transmission mounting
Bolt -A- 80 Nm (59 ft lb) + 90
Bolt -B- 200 Nm (148 ft lb)


34-43




Flange shaft mounting to bracket 25 Nm
(18 ft lb)
Clutch mechanism valve unit to
transmission

5 Nm (44
in. lb)
Selector mechanism mounting
bracket to transmission
20 Nm
(15 ft lb)
Selector mechanism swivel head
to transmission
9 Nm (7 ft
lb)
Back-up light switch to switch unit 20 Nm
(15 ft lb)

34-44




Transmission oiI, checking
Gear oil specification Page 00-3

- Remove insulation tray below
engine/transmission, if equipped.


- Remove plug -arrow- to check oil.

The oil level is correct when the transmission is
full to the lower edge of the filler hole.

- Install plug -arrow-.

When fiIIing with new oiI note foIIowing:

- Remove plug (arrow).


- Top up oil to lower edge of filler hole.


- Fit plug (arrow).

Tightening torque

Oil filler plug 25 Nm (18 ft lb)

34-45





Transmission,
disassembIing
and
assembIing
Sequence for
dismantIing and
assembIing Page
34-53
AssembIy overview
1 - 1st gear
2 - 2nd gear
3 - 3rd gear
4 - 4th gear
5 - 5th gear
6 - Reverse gear

Dismantling
and
assembling
reverse gear
wheel Page
35-49

Removing and
installing
Page 34-53
7 - Output shaft

Dismantling
and
assembling
Page 35-18


34-46





8 - Input shaft

Dismantling
and
assembling
Page 35-1
9 - Transmission
housing

Dismantling
from clutch
housing
Page 34-53

Servicing
Page 34-60
10 - SeIector
mechanism

Dismantling
and
assembling
from Page
Page 34-71
11 - CIutch housing

Servicing
Page 34-65
12 - SIave cyIinder
with reIease
bearing

Removing and
installing
Page 34-53
13 - DifferentiaI

Dismantling
and
assembling
Page 39-7


34-47





14 - FIange shaft
bearing

Removing and
installing
Page 34-29
15 - Right-hand
fIange shaft

Removing and
installing
Page 34-29
16 - Stub shaft

Removing and
installing
Page 39-1
17 - Speedometer
drive gear

Removing and
installing
Page 34-53
18 - FinaI drive ring
gear

Removing and
installing
Page 39-7
19 - Left-hand fIange
shaft

Removing and
installing
Page 34-53


34-48




I - DismantIing and
assembIing gearbox
housing and seIector
mechanism Page
34-49
II - DismantIing and
assembIing input
shaft, output shaft,
differentiaI and
seIector rods Page
34-50

34-49





Transmission
housing and
seIector
mechanism,
removing and
instaIIing
1 - FIange shaft

Removing
Page 34-53

Drive in with
synthetic head
hammer
2 - CircIip

Always renew
page 34-59
3 - BoIt, 25 Nm (18
ft Ib)
4 - Transmission
housing

Servicing
Page 34-60
5 - CIutch housing

Servicing
Page 34-65
6 - Hex boIt, 25 Nm
(18 ft Ib) pIus
90 (1/4 turn)
further
7 - SeIector
mechanism

Dismantling
and
assembling
from Page
Page 34-71
8 - Hex boIt, 25 Nm
(18 ft Ib)


34-50





Input shaft, output
shaft (pinion shaft),
differentiaI and
seIector rods,
disassembIing and
assembIing
1 - SeIector rod
with seIector
fork for 1st and
2nd gear
2 - SeIector rod
with seIector
fork for 5th gear
and reverse
gear
3 - Output shaft

Dismantling
and
assembling
Page 35-18
4 - SeIector rod
with seIector
fork for 3rd and
4th gear
5 - Reverse gear
wheeI

Removing and
installing
Page 35-49


34-51





6 - Input shaft

Dismantling
and
assembling
Page 35-1
7 - SeaIing ring

Qty. 4

Always renew
8 - Guide tube for
reverse gear
9 - VaIve unit, 5 Nm
(44 in. Ib)

Bolt to slave
cylinder pipe
10 - SIave cyIinder
with reIease
bearing
11 - O-ring

Always renew
12 - Hex boIt, 12 Nm
(9 ft Ib)

Qty. 2
13 - Hex nut, 25 Nm
(18 ft Ib) pIus
90 (1/4 turn)
further

4 nuts for
bearing support


34-52





14 - Stub shaft

Removing
Page 34-53

Drive in with
synthetic head
hammer
15 - O-ring

Always renew
16 - FIange shaft
17 - CircIip

Always renew
Page 34-59
18 - Speedometer
drive
19 - CIutch housing

Servicing
Page 34-65
20 - DifferentiaI

Dismantling
and
assembling
Page 39-7


34-53




DisassembIing and assembIing
sequence
Dismantling and assembling transmission
housing, selector mechanism, input shaft,
output shaft (pinion shaft), differential and
selector rods
DisassembIing

- Drain gearbox oil.



- Mount gearbox on repair stand.
- Remove slave cylinder with release bearing
(arrows).



- Remove left flange shaft
Screw in M10 x 75 bolts (arrows) alternately.

34-54





- Remove both bolts (arrows) for the reverse
gear wheel mounting bracket.



- Remove selector mechanism, to do this
place selector shaft in neutral position. Then
remove bolts (arrows) and pull selector shaft
out from the gearbox housing.


34-55





- Remove gearbox housing to clutch housing
securing bolts -A- in area of differential.



- Remove bolts -A-, from inside clutch
housing for securing clutch housing to
gearbox housing.
Note:
Do not remove nuts -B- for output shaft bearing
support.

34-56





- Take-off gearbox housing, carefully lever up
all round and alternating between sides on
the protruding flange (arrows), if necessary,
do not damage sealing surfaces.
- When taking off, pull pull rod out from
locking unit.



- Swing reverse gear wheel in direction of
arrow -A- and take off.
- Remove guide tube for reverse gear, arrow -
B-.
- Remove nuts for output shaft bearing
support ( Page 34-55 Item -B-, Illustration
N34-0373).


34-57





- Take off input shaft -A-, output shaft -B- and
selector rods -C- together from clutch
housing.



- Remove stub shaft, right (shown here with
gearbox installed).
A - Separating device Kukko 17/0
B - Separating device Kukko 17/1
1 - Bolt M10 x 80 (Qty. 2)
- Turn bolts -1- evenly against separating
device -B-.
- Remove speedometer drive.
- Take out differential.


34-58



AssembIing

- Install differential.


- Install speedometer drive.



- Always renew sealing rings (arrows) for output
shaft bearing support.
Note:
The illustration only shows 2 of the 4 sealing
rings.
- Install input shaft, output shaft and selector
rods together.
Note:
Align with holes in clutch housing when inserting
output shaft bearing support. Do not damage
input shaft seal.
- Tighten nuts for output shaft bearing support.
- Install guide tube for reverse gear.
- Install reverse gear wheel.


34-59





- Install M8 x 80 mm studs in clutch housing -
arrows-, so that when installing transmission
housing stop sleeves are aligned to selector
rods.
- Install transmission housing.
- Place selector plates in neutral.
- Install selector mechanism.



- Replace securing rings for flange shaft
and/or stub shaft.
- Using vice clamps, clamp flange shaft or
stub shaft in a vice. Press old circlip out from
groove with new circlip -A-.
- Drive in left-hand flange shaft as well as
right-hand stub shaft with a synthetic head
hammer.
- Install slave cylinder with release bearing.

34-60





Transmission
housing,
repairing
1 - Transmission
housing

If replaced:
Adjust input
shaft, output
shaft and
differential
Page 39-24
2 - SeaIing ring

Always renew
3 - OiI fiIIer pIug, 25
Nm (18 ft Ib)
4 - Shim

For output
shaft

Adjustment
overview
Page 39-24
5 - Outer
race/tapered
roIIer bearing

For input shaft

Removing and
installing
from Page 35-
11

If replaced:
Adjust input
shaft Page
35-13


34-61





6 - Outer
race/tapered
roIIer bearing

For output
shaft

Removing and
installing
from Page 35-
40

If replaced:
Adjust output
shaft Page
35-42
7 - Shim S2

For output
shaft

Adjustment
overview
Page 39-24
8 - Outer
race/tapered
roIIer bearing

For differential

Removing and
installing
from Page 39-7

If replaced:
Adjust
differential
Page 39-25
9 - Shim

For differential

Adjustment
overview
Page 39-24


34-62





10 - Locking unit

For reverse
gear

Removing
Fig. 1

Driving in
Fig. 2
11 - Stop sIeeves

Removing
Fig. 3

Drive in with
synthetic head
hammer
12 - SeaIing ring

Renewing
Page 39-1


34-63





Fig. 1 Locking unit for reverse gear,
removing
A - Ball joint splitter (commercial type) e.g.
Kukko No. 128/2
B - Hex nut M10



Fig. 2 Reverse gear Iocking unit, driving
in onto stop


34-64





Fig. 3 Stop sIeeves, removing
A - Puller Kukko 204-1
- Tension puller when assembling (arrow)
then using a lever under puller, lever stop
sleeve out.

34-65





Servicing
cIutch
housing
1 - Hex boIt, 25 Nm
(18 ft Ib)
2 - OiI pan

Installing Fig.
1
3 - SeIector rod
guide

Installing Fig.
1
4 - Outer
race/tapered
roIIer bearing

For output
shaft

Removing and
installing
Page 35-26

If replaced:
Adjust output
shaft Page
35-42
5 - Shim S1

For output
shaft

Adjustment
overview
Page 39-24


34-66





6 - Outer
race/tapered
roIIer bearing

For input shaft

Removing and
installing
Page 35-5

If replaced:
Adjust input
shaft Page
35-13
7 - Magnet

Held in place
by housing joint
surface
8 - DoweI sIeeve

(Qty. 2)
9 - Protective cap
10 - Input shaft oiI
seaI

Removing
Fig. 2

Installing Fig.
3
11 - Bonded rubber
mounting

Pulling out
Fig. 4

Pulling in Fig.
5


34-67





12 - OiI seaI

Renewing
Page 39-1
13 - Guide bushing
14 - Drive shaft with
pinion

For
speedometer
15 - CIutch housing

If replaced:
Adjustment
overview, Page
39-24
16 - SeaIing ring

Always renew
17 - OiI drain pIug,
25 Nm (18 ft Ib)
18 - OiI defIector
ring

Installation
position: Step
on internal
diameter points
to seal
19 - Outer
race/tapered
roIIer bearing

For differential

Removing and
installing
from Page 39-7

If replaced:
Adjust
differential
Page 39-25


34-68





Fig. 1 OiI pan and seIector rod guide,
instaIIing
- Insert selector rod guide -A- with centralizing
shoulder into hole in clutch housing.
- Insert oil pan -B- into housing cut-out next to
differential taper roller bearing outer race.
- Secure oil pan and selector rod guide with a
hexagon head bolt -C-.



Fig. 2 Output shaft oiI seaI, removing
- Lever oil seal out carefully with a
screwdriver.


34-69





Fig. 3 Input shaft oiI seaI, driving in



Fig. 4 Bonded rubber mounting, puIIing
out
Note:
It is important to grease spindle with
Molybdenum grease before using.

34-70





Fig. 5 Bonded rubber mounting, puIIing
in
A - Bonded rubber mounting

34-71





DismantIing
and
assembIing
gearbox
seIector
mechanism
1 - Hexagon nut, 20
Nm
2 - Gear seIector
Iever

Install so that
the master
spline aligns
with selector
shaft

Can be
replaced with
the selector
mechanism
installed
3 - OiI seaI

Removing
Fig. 1

Installing Fig.
2
4 - Reversing Iight
switch, 20 Nm
5 - SeaIing ring

Always renew
6 - Cap

For gearbox
breather
7 - SeIector unit


34-72





Fig. 1 Removing seIector shaft seaI



Fig. 2 InstaIIing oiI seaI onto stop

35-1





Input shaft,
disassembIing
and
assembIing
Note:

When installing new
gear wheels,
consult technical
data Page 00-3 .

If the position of the
taper roller bearings
is affected when
exchanging parts,
the input shaft must
be re-adjusted. See
adjustment
overview Page
39-24
1 - CIutch housing
2 - Tapered roIIer
bearing outer
race

Pulling out
Fig. 1

Pressing in
Fig. 2
3 - Tapered roIIer
bearing inner
race

Pressing off
Fig. 6

Pressing on
Fig. 7


35-2





4 - Input shaft

Adjusting
Page 35-13
5 - NeedIe roIIer
bearing

For 3rd gear
6 - 3rd gear wheeI
7 - 3rd gear
synchro-ring

Checking for
wear Fig. 8
8 - Locking coIIar
with 3rd and 4th
gear synchro-
hub

Press off with
3rd gear wheel
Fig. 5

Dismantling
Fig. 9

Assembling
locking
collar/synchro-
hub Fig. 9
and Fig. 10

Pressing on
Fig. 11
9 - CircIip


35-3





10 - 4th gear
synchro-ring

Checking for
wear Fig. 8
11 - NeedIe roIIer
bearing

For 4th gear
12 - 4th gear wheeI
13 - 5th gear wheeI

Pressing off
Fig. 4

Pressing on
Fig. 12
14 - CircIip
15 - Tapered roIIer
bearing inner
race

Pulling off
Fig. 3

Pressing on
Fig. 13
16 - Outer
race/tapered
roIIer bearing

Pulling out
Fig. 14

Pressing in
Fig. 15


35-4





17 - Shim

Determining
thickness
Page 39-25
18 - Transmission
housing
19 - Spring

Installation
position Fig.
10
20 - Lock pieces
(Qty. 3)

Installation
position Fig.
9
21 - Synchro-hub
22 - Locking coIIar
23 - Spring

Installation
position Fig.
10


35-5





Fig. 1 Tapered roIIer bearing outer race,
puIIing out
A - Internal extractor, e.g. Kukko 21/6, 37 ... 46
mm
B - Counter support, e.g. Kukko 22/2


Fig. 2 Tapered roIIer bearing outer race,
pressing in


35-6





Fig. 3 Tapered roIIer bearing inner race,
puIIing off



Fig. 4 5th gear wheeI, pressing off
A - Separating device 22 ... 115 mm, e.g.
Kukko 17/2

35-7





Fig. 5 3rd and 4th gear synchro hub and
Iocking coIIar with 3rd gear
sIiding wheeI, pressing off



Fig. 6 Tapered roIIer bearing inner race,
pressing off
A - Separating device 12 ... 75 mm, e.g. Kukko
17/1

35-8





Fig. 7 Tapered roIIer bearing inner race,
pressing on



Fig. 8 Synchro-ring, checking for wear
- Press synchro-ring onto the gear wheel
cone and measure gap "a" with feeler
gauge.
Gap "a" New dimension Wear limit
3rd gear
4th gear
1.0 ... 1.7 mm
1.0 ... 1.7 mm

0.5 mm


35-9





Fig. 9 3rd and 4th gear Iocking coIIar
and synchro-hub, disassembIing
and assembIing
1 - Spring
2 - Locking piece
3 - Locking collar
4 - Synchro-hub
- Slide locking collar over synchro-hub.
The recesses for locking pieces in synchro-hub
and locking collar must align.


Fig. 10 3rd and 4th gear Iocking
coIIar/synchro-hub, assembIing
The locking collar has been pushed over the
synchro-hub.
- Insert locking pieces and install springs
120 off-set. The angled end of the spring
must locate in the hollow locking piece.


35-10





Fig. 11 3rd and 4th gear synchro-hub
with Iocking coIIar, pressing on



Fig. 12 5th gear wheeI, pressing on


35-11





Fig. 13 Tapered roIIer bearing inner race,
pressing on



Fig. 14 Tapered roIIer bearing outer race,
puIIing out of transmission
housing
A - Internal puller 46 ... 58 mm, e.g. Kukko
21/7
B - Counter support, e.g. Kukko 22/2

35-12





Fig. 15 Tapered roIIer bearing outer race,
pressing into transmission
housing
- Fit shim under outer race.
- Support gearbox housing with press piece
3062 directly below bearing support.

35-13




Input shaft, adjusting
(Determining thickness of shim for input shaft)
It is only necessary to readjust the input shaft
when


Gearbox housing



Clutch housing



Input shaft

or the


Taper roller bearing

is renewed.
Adjustment overview Page 39-24

- Press taper roller bearing outer race without
shim into gearbox housing onto stop, using
VW 433.


- Install input shaft in clutch housing and
assemble gearbox housing. Tighten hexagon
head bolts to 25 Nm and then turn 90
further.



- Fit measuring appliance and D.T.I. in clutch
housing (large taper roller bearing in gearbox
housing).


35-14




- Before taking any measurements rotate input
shaft to allow bearing to settle. Set D.T.I. to
"O" with 1 mm preload.

Note:
This preparation is to be repeated for each
subsequent measurement, otherwise the gauge
will not return to the starting position.


- Press input shaft in direction of D.T.I.
- Read off and note play indicated on D.T.I.
(example 0.975).
Note:
D.T.I. does not return to original position.
- Determine thickness of shim from table
Page 35-15 (example 0.875).
- Remove input shaft and pull taper roller
bearing outer race out from gearbox housing.
- Press taper roller bearing outer race together
with 0.875 shim into gearbox housing using
VW 433.
- Assemble gearbox housing and tighten
hexagon head bolts to 25 Nm and then turn
90 further.


35-15



TabIe of shims

Bearing pIay Shim
Measured
vaIue
(mm)
Thickness
(mm)
Part No.
0.695 ... 0.769
0.770 ... 0.794
0.795 ... 0.819
0.650
0.675
0.700
02F 311
391
02F 311 391
A
02F 311 391
B
0.820 ... 0.844
0.845 ... 0.869
0.870 ... 0.894
0.725
0.750
0.775
02F 311 391
C
02F 311 391
D
02F 311 391
E
0.895 ... 0.919
0.920 ... 0.944
0.945 ... 0.969
0.800
0.825
0.850
02F 311 391
F
02F 311 391
G
02F 311 391
H
0.970 ... 0.994
0.995 ... 1.019
1.020 ... 1.044
0.875
0.900
0.925
02F 311 391
J
02F 311 391
K
02F 311 391
L
1.045 ... 1.069
1.070 ... 1.094
1.095 ... 1.119
0.950
0.975
1.000
02F 311 391
M
02F 311 391
N
02F 311 391
P
1.120 ... 1.144
1.145 ... 1.169
1.170 ... 1.194
1.025
1.050
1.075
02F 311 391
Q
02F 311 391
R
02F 311 391
S
1.195 ... 1.219
1.220 ... 1.244
1.245 ... 1.269
1.100
1.125
1.150
02F 311 391
T
02F 311 391
AA
02F 311 391
AB


35-16




Bearing pIay Shim
Measured
vaIue
(mm)
Thickness
(mm)
Part No.
1.270 ...
1.294
1.295 ...
1.319
1.320 ...
1.344
1.175
1.200
1.225
02F 311
391 AC
02F 311
391 AD
02F 311
391 AE
1.345 ...
1.369
1.370 ...
1.394
1.395 ...
1.419
1.250
1.275
0.650 + 0.650 =
1.300
02F 311
391 AF
02F 311
391 AG
02F 311
391 + 391
1.420 ...
1.444
1.445 ...
1.469
1.470 ...
1.494
0.650 + 0.675 =
1.325
0.675 + 0.675 =
1.350
0.675 + 0.700 =
1.375
02F 311
391 + A
02F 311
391 A + A
02F 311
391 A + B
1.495 ...
1.519
1.520 ...
1.544
1.545 ...
1.569
1.570 ...
1.590
0.700 + 0.700 =
1.400
0.700 + 0.725 =
1.425
0.725 + 0.725 =
1.450
0.725 + 0.750 =
1.475
02F 311
391 B + B
02F 311
391 B + C
02F 311
391 C + C
02F 311
391 C + D


35-17




Checking measurement


- Install measuring appliance and D.T.I.
- Rotate input shaft so that the taper roller
bearing settles.
- Press input shaft in direction of arrow.
- Bearing play should be min. 0.04 ... max. 0.12
mm.
Note:
If the bearing clearance cannot be measured, but
input shaft play is perceptible and the input shaft
turns freely, the adjustment is acceptable.


- Frictional moment (bearing preload) max. 20
Ncm.
A - Commercial torque gauge 0 ... 600 Ncm
B - Extension for 1/2 " square drive socket
35-18





Output shaft,
disassembIing
and
assembIing
Notes:

When installing new
gear wheels or a
new output shaft
consult technical
data Page 00-3 .

If the output shaft or
taper roller bearings
have been renewed
then carry out
output shaft
adjustment Page
35-42 .
1 - Hex nut, 25 Nm
(18 ft Ib) pIus
90 (1/4 turn)
further

4 nuts for
bearing support
2 - CIutch housing
3 - Shim S1

Determining
thickness
Page 35-42
4 - SmaII tapered
roIIer bearing
outer race

Pulling out
Fig. 1

Pressing in
Fig. 2


35-19





5 - SmaII tapered
roIIer bearing
inner race

Pulling off
Fig. 3

Pressing on
Fig. 4
6 - Output shaft

Is paired with
final drive gear
wheel, always
renew together
as a set

Adjusting
Page 35-42
7 - Large tapered
roIIer bearing
inner race

Pressing off
Fig. 10

Pressing on
Fig. 13
8 - Large tapered
roIIer bearing
outer race

Pressing out
Fig. 11

Pressing in
Fig. 12


35-20





9 - SeaIing ring

Place sealing
rings (Qty. 4)
on the bearing
support bolts
10 - Bearing support
11 - NeedIe roIIer
bearing

For 1st gear
12 - 1st gear wheeI

Installation
position Fig.
16
13 - Synchro-ring

(1st gear inner
ring)

Checking for
wear Fig. 14

Check lugs for
scoring

Installation
position Fig.
16
14 - 1st gear outer
ring

Insert in the
synchro-ring
(item 13 )

Installation
position Fig.
16

Renew if
scored


35-21





15 - 1st gear
synchro-ring

Checking for
wear Fig. 15

Installation
position Fig.
16
16 - 1st and 2nd
gear Iocking
coIIar with
synchro-hub

After removing
securing clip
(item 17 ) pull
off over bearing
support Fig.
9

Dismantling
Fig. 17

Assembling
locking
collar/synchro
hub Fig. 17
and Fig. 18

Installation
position Fig.
19

Pressing on
Fig. 20
17 - Securing cIip
18 - 2nd gear
synchro-ring

Checking for
wear Fig. 15

Assemble so
that the
recesses locate
in the locking
collar (item 16 )
locking pieces


35-22





19 - Outer ring

Insert in the
synchro-ring
(item 18 ),
installation
position Fig.
21

Renew if
scored
20 - Synchro-ring

(Inner ring)

Checking for
wear Fig. 14

Check lugs for
scoring

Installation
position Fig.
22
21 - 2nd gear wheeI

Installation
position Fig.
23
22 - NeedIe roIIer
bearing

For 2nd gear


35-23





23 - 3rd gear wheeI

Press off with
2nd gear
sliding wheel
Fig. 8

Pressing on
Fig. 24

Shoulder points
to 4th gear
24 - 4th gear wheeI

Pressing off
Fig. 7

Pressing on
Fig. 25

Shoulder points
to 3rd gear
25 - CircIip
26 - NeedIe roIIer
bearing

For 5th gear
27 - 5th gear wheeI

Press off
together with
locking
collar/synchro
hub Fig. 6
28 - 5th gear
synchro-ring

Check for wear
Fig. 26


35-24





29 - 5th and reverse
gear Iocking
coIIar with
synchro-hub

Press off with
5th gear sliding
wheel (item 27
) Fig. 6

Dismantling
Fig. 17

Installation
position locking
collar/synchro-
hub Fig. 27

Assembling
locking
collar/synchro
hub Fig. 17
and Fig. 18

Pressing on
Fig. 28
30 - CircIip
31 - Reverse gear
synchro-ring

Check for wear
Fig. 26
32 - NeedIe roIIer
bearing

For reverse
gear wheel
33 - Reverse sIiding
gear wheeI


35-25





34 - Thrust washer
35 - Tapered roIIer
bearing inner
race

Press off with
reverse gear
wheel Fig. 5

Pressing on
Fig. 29
36 - Outer
race/tapered
roIIer bearing

Pulling out
Fig. 30

Pressing in
Fig. 31
37 - Shim S2

Determining
thickness
Page 35-45
38 - Transmission
housing


35-26





Fig. 1 SmaII tapered roIIer bearing outer
race, puIIing out
A - Internal puller 46 ... 58 mm, e.g. Kukko
21/7
B - Counter support, e.g. Kukko 22/2


Fig. 2 Tapered roIIer bearing outer race,
pressing in


35-27





Fig. 3 SmaII tapered roIIer bearing inner
race, pressing off
- Fit gripping device and tension behind
bearing rollers, then turn bearing and
retension gripping device.



Fig. 4 SmaII tapered roIIer bearing inner
race, pressing on


35-28





Fig. 5 Tapered roIIer bearing inner race,
pressing off
- Press off taper roller inner race via reverse
gear wheel.
Note:
Before pressing off, slide locking collar over to
5th gear.


Fig. 6 5th gear and reverse gear Iocking
coIIar/synchro hub, pressing off
A - Separating device 22 ... 115 mm, e.g.
Kukko 17/2
After removing securing ring press 2nd gear
sliding wheel and locking collar/synchro-hub off
together.

35-29





Fig. 7 4th gear wheeI, pressing off
- First remove securing clip.



Fig. 8 3rd gear wheeI, pressing off
- Press off 3rd gear wheel via 2nd gear wheel.
Note:
Before pressing off, slide locking collar over to
1st gear.

35-30





Fig. 9 Locking coIIar with synchro-hub,
puIIing off via bearing support
A - Two-arm puller, e.g. Kukko 20/10 with 250
mm reach hooks
Note:
Remove circlip before pulling off individual
components.


Fig. 10 Large tapered roIIer bearing inner
race, pressing off
- Before starting press sequence, tension
gripping device V.A.G. 1582/1 onto inner
race.


35-31





Fig. 11 Large tapered roIIer bearing outer
race, pressing out from bearing
support



Fig. 12 Large tapered roIIer bearing outer
race, pressing into bearing
support


35-32





Fig. 13 Large tapered roIIer bearing inner
race, pressing on
Note:
Press piece 3118 step points towards taper
roller bearing inner race.


Fig. 14 1st and 2nd gear inner-ring,
checking for wear
- Press inner ring onto gear wheel cone and
measure gap "a" with a feeler gauge.
Gap "a" New dimension Wear
limit
1st and 2nd
gear
0.75 ... 1.25
mm
0.3 mm


35-33





Fig. 15 1st and 2nd gear synchro-ring,
checking for wear
- Press synchro-ring, outer-ring and inner-ring
onto gear wheel cone and measure gap "a"
with feeler gauge.
Gap "a" New
dimension
Wear
limit
1st and 2nd
gear
1.2 ... 1.8 mm 0.5 mm



Fig. 16 Outer ring, inner ring and 1st gear
synchro ring, instaIIation position
- Place inner ring -A- on 1st gear sliding
wheel.
The angled lugs (arrow 1) point towards outer
ring -B-.
- Fit outer ring -B-.
The lugs (arrow 2) engage in the sliding wheel
recesses (arrow 3).
- Fit synchro-ring -C-.
The grooves (arrow 4) engage in the inner ring
-A- lugs (arrow 1).

35-34





Fig. 17 Locking coIIar and synchro hub,
disassembIing and assembIing
1 - Spring
2 - Locking collar
3 - Synchro-hub
4 - Locking piece
- Slide locking collar over synchro-hub.
The recesses for locking pieces in synchro-hub
and locking collar must align.


Fig. 18 Locking coIIar and synchro hub,
assembIing
The locking collar has been pushed over the
synchro-hub.
- Insert locking pieces and install springs
120 off-set. The angled end of the spring
must locate in the hollow locking piece.


35-35





Fig. 19 1st and 2nd gear Iocking
coIIar/synchro-hub, instaIIation
position
The wider shoulder of the synchro-hub (arrow)
faces towards 2nd gear.


Fig. 20 1st and 2nd gear Iocking
coIIar/synchro-hub, pressing on


35-36





Fig. 21 2nd gear outer-ring, instaIIation
position
The lugs (arrows) face to 1st gear -A-


Fig. 22 Synchro ring -A- (inner ring for
2nd gear), instaIIation position
The lugs (arrow 1) locate in the recesses
(arrow 2) in the synchro-ring -B-.

35-37





Fig. 23 2nd gear wheeI, instaIIation
position
The higher shoulder -A- faces to 1st gear -B-.
The recesses in the shoulder (arrows) locate in
the lugs of the outer ring (arrow Fig. 21 )


Fig. 24 3rd gear wheeI, pressing on
Shoulder points towards 4th gear.

35-38





Fig. 25 4th gear wheeI, pressing on
Shoulder points to 3rd gear.
- Fit securing ring.



Fig. 26 Synchro ring, checking for wear
- Press synchro-ring onto the gear wheel
cone and measure gap "a" with feeler
gauge.
Gap "a" New
dimension
Wear
limit
5th gear and
reverse gear

1.0 ... 1.7
mm

0.5 mm


35-39





Fig. 27 5th gear and reverse gear Iocking
coIIar/synchro hub, instaIIation
position
The wider synchro hub shoulder with chamfer
(arrow) faces towards 5th gear sliding wheel.


Fig. 28 5th gear and reverse gear Iocking
coIIar with synchro hub, pressing
on


35-40





Fig. 29 Tapered roIIer bearing inner race,
pressing on



Fig. 30 Tapered roIIer bearing outer race,
puIIing out from transmission
housing
A - Internal extractor 37 ... 46 mm, e.g. Kukko
21/6
B - Counter support, e.g. Kukko 22/2

35-41





Fig. 31 Tapered roIIer bearing outer race,
pressing into transmission
housing
- Fit shim under outer race.
- Support gearbox housing with press piece
3062 directly below bearing support.

35-42




Output shaft, adjusting
(Determining output shaft shims S1 and S2)
It is necessary to readjust the output shaft when



Final drive



Clutch housing



Gearbox housing



Bearing support

or


Taper roller bearing

have been changed.
Adjustment overview Page 39-24
Shim S1, determining

- Press small taper roller bearing outer race
together with a 0.65 mm thick shim fully into
clutch housing Page 35-26 .


- Insert output shaft and tighten bearing
support to 25 Nm and then turn 90 further.


35-43





- Mount D.T.I. (3 mm measuring range) and
"O" with 1 mm preload.
- Move output shaft up and down and recall
dial gauge reading (example: 0.30 mm)
Note:
Do not turn the output shaft whilst measuring,
otherwise the bearing will settle and a false
reading will be given.
Determining thickness of shim
The specified bearing preload is obtained by
adding a constant figure to the reading
obtained: (0.30 mm) and the thickness of the
shim installed (0.65 mm).
Example:
Shim installed 0.65 mm
+ Reading 0.30 mm
+ Preload (constant) 0.20 mm
S1 shim thickness 1.15 mm



- Remove output shaft and pull out small
taper roller bearing outer race.


35-44



The following adjustment shims are available:

Size (mm) Part No.
0.65
0.70
02A 409 210
02A 409 210 A
0.75
0.80
0.85
02A 409 210 B
02A 409 210 C
02A 409 210 D
0.90
0.95
1.00
02A 409 210 E
02A 409 210 F
02A 409 210 G
1.05
1.10
1.15
02A 409 210 H
02A 409 210 J
02A 409 210 K
1.20
1.25
1.30
02A 409 210 L
02A 409 210 M
02A 409 210 N
1.35
1.40
02A 409 210 P
02A 409 210 Q

Varying tolerances make it possible by
measuring the shims to obtain the exact shim
thickness required.

- Press in small taper roller bearing outer race
together with the determined shim (in
example 1.15 mm) Page 35-26 .


35-45



Shim S2, determining

- Complete output shaft.


- Insert output shaft without bearing support O
ring and tighten bearing support nut to 25 Nm
then turn 90 further.



- Attach measuring assembly to 3rd gear wheel.
A - Measuring gauge extension from VW 2066
- Press taper roller bearing outer race with a
0.65 mm shim into gearbox housing onto stop,
using 30-26.
- Fit gearbox housing and tighten bolts to torque
setting.



- Mount D.T.I. and "0" with 1 mm preload.
A - Measuring gauge extension from VW 2066
Notes:

Measuring gauge extension must be against
output shaft measuring assembly as
illustrated on illustration N35-0169.

Do not turn output shaft when measuring.


35-46





- Loosen bearing support hexagon nuts -B-
using cross-over sequence until the nuts
release the output shaft.
- Read off play on gauge and note reading
(example: 0.30 mm)
Determining thickness of shim
The specified bearing preload is obtained by
adding to the reading obtained: (0.30 mm) and
the thickness of the shim installed (0.65 mm) a
preload constant of (0.10 mm).
ExampIe:
Shim installed 0.65 mm
+ Reading 0.30 mm
+ Preload (constant) 0.10 mm
S2 shim thickness 1.05 mm


35-47





- Remove gearbox housing and pull taper
roller bearing outer race out from gearbox
housing.
- Insert shims of correct thickness, thickest
shim first.
The following shims are available:
Size (mm) Part No.
0.65
0.70
0.75
020 311 391 P
020 311 391 Q
020 311 391
0.80
0.85
0.90
020 311 391 A
020 311 391 B
020 311 391 C
0.95
1.00
1.05
020 311 391 D
020 311 391 E
020 311 391 F
1.10
1.15
1.20
020 311 391 G
020 311 391 H
020 311 391 J
1.25
1.30
1.35
020 311 391 K
020 311 391 L
020 311 391 M
1.40
0.70+0.75 = 1.45
0.75+0.75 = 1.50
020 311 391 N
020 311 391 Q/391
020 311 391/391
0.75+0.80 = 1.55 020 311 391/391 A


35-48




- Press outer race in again.


- Remove output shaft and engage 4th gear
using locking collar.


- Insert input shaft together with output shaft.
Tighten bearing support nut in clutch housing
to 25 Nm and then turn 90 further.


- Install gearbox housing and tighten hexagon
head bolts to 25 Nm and then turn 90 further.

Checking friction moment


A - Commercially available torque gauge 0 ... 600
Ncm
B - Extension for 1/2 " square drive socket
For new taper roller bearings the friction moment
must be 130 ... 180 Ncm.
For used taper roller bearings the friction moment
must be at least 30 Ncm.
Note:
Lubricate bearings with gearbox oil before
checking friction moment.
35-49





Reverse gear
wheeI,
removing and
instaIIing
1 - Transmission
housing
2 - Shaft

Press out from
mounting (item
6 ) with reverse
gear wheel
Fig. 1

Pressing in
Fig. 2
3 - Reverse gear
wheeI
4 - NeedIe roIIer
bearing
5 - Thrust washer


35-50





6 - Reverse gear
mounting

Removing and
installing
Page 34-53
7 - Reverse gear
guide tube

Removing and
installing
Page 34-53
8 - CIutch housing


35-51





Fig. 1 Reverse gear wheeI, pressing out
from mounting
A - Separating device 12 ... 75 mm, e.g. Kukko
17/1


Fig. 2 Reverse gear wheeI shaft,
pressing into mounting

39-1




OiI seaI for stub shaft or
fIange shaft, removing and
instaIIing
(Gearbox installed)
To renew the left-hand flange shaft or right-hand
stub shaft seal the relevant drive shaft must be
removed as follows:

- Fit support device 3250 before lifting vehicle.


Repair Manual, Suspension, Wheels, Brakes,
Steering m.y. 1992-1996, Repair Group 40,
Servicing front suspension


- Remove hexagon bolt (arrow) for drive
shaft/wheel hub and loosen wheel securing
bolts
- Remove noise insulation tray.
- Disconnect drive shaft from flanged shaft.
- Remove wheel.



- Disconnect wheel bearing housing/lower ball
joint bolted connection.
- Remove bolt for shock absorber/anti-roll bar
coupling link.
- Press drive shaft out of wheel bearing
housing.


39-2



When repIacing Ieft-hand oiI seaI:

- Removing drive shaft Page 39-1 .



- Remove flange shaft, to do this screw 2 bolts
-A- in alternatively.
- Always renew flange shaft circlip Page 34-
59 .



- Pull flange shaft oil seal out using VW 771
and VW 771/37.
Note:
Do not damage oil deflector ring when pulling
out.

39-3





- Drive new seal in onto stop.
- Fill space between seal and dust lip with
multi-purpose grease.
- Drive in flange shaft.
- Install drive shaft.
- Check gearbox oil Page 34-44
- Install noise insulation tray.


39-4



When repIacing right-hand oiI seaI:

- Remove drive shaft Page 39-1 .



- Unbolt flange shaft mounting -A- from
bracket -B-.
- Pull right-hand flange shaft -C- out from stub
shaft -D-.
- Take O ring out from stub shaft.



- Removing stub shaft.
A - Separating device Kukko 17/0
B - Separating device Kukko 17/1
1 - Bolt M10 x 80 (Qty. 2)
- Turn bolts -1- evenly against separating
device -B-.


39-5




- Lever seal out.



- Drive new seal in onto stop.
- Fill space between seal and dust lip with
multi-purpose grease.
- Always renew stub shaft circlip Page 34-59
.
- Drive stub shaft in complete with new circlip
and O ring with synthetic head hammer.
Note:
Grease stub shaft internal splines with drive
shaft grease G 000 603.
- Install right-hand flange shaft.
- Install drive shaft.
- Check gearbox oil Page 34-44
- Install noise insulation tray.


39-6



Tightening torque:

Drive shaft to drive flange 80 Nm
Wheel bearing housing to lower
ball joint
55 Nm
Hexagon bolt on drive shaft 150 Nm +
90
Flange shaft mounting to
bracket
25 Nm











39-7





DismantIing
and
assembIing
differentiaI
Notes:

Heat taper roller
bearing inner race
to 100 C before
installing.

Always renew both
taper roller bearings
together as a set.

If differential
housing, gearbox
housing or clutch
housing taper roller
bearings are
renewed adjust
differential Page
39-25 .
1 - Gearbox
housing
2 - Shim

For differential

Determining
thickness
Page 39-25


39-8





3 - Taper roIIer
bearing outer
race

Pulling out
Fig. 5

Pressing in
Fig. 6
4 - Taper roIIer
bearing inner
race

Pulling off
Fig. 3

Pressing on
Fig. 4
5 - DifferentiaI
housing

With rivetted
final drive gear

When renewing
final drive gear
drill out rivet
heads Fig. 7

Attaching final
drive gear with
bolts Fig. 10
6 - Speedometer
drive gear

Fit on
differential
housing before
pressing on
inner race


39-9





7 - Taper roIIer
bearing inner
race

Pulling off
Fig. 3

Pressing on
Fig. 4
8 - Taper roIIer
bearing outer
race

Pressing out
Fig. 1

Pressing in
Fig. 2
9 - OiI defIector
ring

Press out with
taper roller
bearing outer
race (item 8 )
Fig. 1
10 - CIutch housing
11 - OiI seaI

Renewing
Page 39-1


39-10





12 - O-ring

Always renew

Insert into stub
shaft groove
(item 14 )
13 - Dust pIate

For stub shaft

Pressing off
Fig. 17

Pressing on
Fig. 18
14 - Stub shaft

Removing and
installing
Page 39-1

Grease internal
splines with
drive shaft
grease G 000
603
15 - CircIip

Always renew
16 - Right-hand
fIange shaft

Removing and
installing
Page 39-1


39-11





17 - FIange shaft
bearing

Pressing off
Fig. 15

Pressing on
Fig. 16
18 - CircIip
19 - Dust pIate

For flange shaft

Pressing off
Fig. 13

Pressing on
Fig. 14
20 - One-piece
thrust washer

Coat with
gearbox oil
when installing
21 - Sun wheeIs

Installing Fig.
12
22 - PIanet pinion

Installing Fig.
12


39-12





23 - Spring pin

For securing
planet pinion
axis shaft

Removing and
installing Fig.
11
24 - PIanet pinion
axis shaft

Knock out with
drift
25 - CircIip

Always replace
26 - FIange shaft

Removing and
installing
Page 39-1
27 - OiI seaI

Renewing
Page 39-1
28 - Hexagon nut, 60
Nm and turn
90 further


39-13





29 - FinaI drive gear
wheeI

Rivetted in
production

Bolted Fig.
10

Heat to 100 C
before
installing

Pressing off
Fig. 8

Fit to
differential
housing Fig.
9

Is paired with
output shaft,
only renew as
a set
30 - DifferentiaI
housing

Bolt to final
drive gear
wheel Fig. 10
31 - BoIt


39-14





Fig. 1 Pressing taper roIIer bearing
outer race -A- out from cIutch
housing
B - Internal puller 46...58 mm, e.g. Kukko 21/7
Note:
After pressing out, check oil deflector ring for
damage and renew if necessary.


Fig. 2 Pressing taper roIIer bearing
outer race into cIutch housing
- First insert oil deflector ring.


39-15





Fig. 3 PuIIing off taper roIIer bearing
inner race
- Before fitting the extractor position press
piece 40-105 on differential housing.
Note:
Pulling off both taper roller bearing inner races
from differential housing is identical.


Fig. 4 Pressing on taper roIIer bearing
inner race
Note:
The taper roller bearing inner races for
gearbox housing and clutch housing are
pressed on with the same press tools.

39-16





Fig. 5 PuIIing taper roIIer bearing outer
race out from gearbox housing
A - Internal puller 56...70 mm, e.g. Kukko 21/8
B - Counter support, e.g. Kukko 22/2


Fig. 6 Pressing taper roIIer bearing
outer race into gearbox housing
- Fit shim under outer race.
- Support gearbox housing with sleeve 30-14
directly below bearing support.


39-17





Fig. 7 Rivet heads, driIIing out
- Drill out rivet heads with 12 mm drill from
countersunk side and knock-out with drift.
Note:
Clean differential before and after drilling,
protect taper roller bearing from drillings.


Fig. 8 Pressing off finaI drive gear
- Place thrust piece 40-105 on differential
housing.


39-18





Fig. 9 Heating finaI drive gear wheeI to
approx. 100 C and instaIIing
- Use bolts -A- from repair kit to guide final
drive gear into position during installation.



Fig. 10 BoIting finaI drive gear and
differentiaI housing together
Use special bolts with nuts according to parts
catalog.

39-19





Fig. 11 Removing and instaIIing pIanet
wheeI axis shaft spring pin
Removing
- Cover taper roller bearing inner race and
speedometer drive gear to avoid possible
damage and ingress of metal particles.
- Knock-out spring pin with chisel, inserting
chisel into circumferential groove.
InstaIIing
- Knock fully into the differential housing.


39-20





Fig. 12 InstaIIing sun wheeIs and pIanet
pinions
- Lubricate one piece thrust washer with
gearbox oil and install.
- Install both sun wheels and secure (e.g. with
flange shaft).
- Insert planet wheels turned through 180
and pivot into position.
- Drive planet wheel axle into final position
and secure with spring pin.



Fig. 13 Pressing off fIange shaft dust
pIate


39-21





Fig. 14 Pressing on fIange shaft dust
pIate
- Press new dust plate on until it is flush with
shoulder -arrow-.



Fig. 15 Pressing fIange shaft mounting
off
- Remove circlip on bearing first.


39-22





Fig. 16 Pressing on fIange shaft bearing
- Install circlip.



Fig. 17 Pressing stub shaft dust pIate off


39-23





Fig. 18 Pressing stub shaft dust pIate on

39-24



Adjustment overview
Note:
If repairs have been carried out to the gearbox it is only necessary to adjust the input shaft,
output shaft or differential if components have been renewed which have a direct effect on the
adjustment of the gearbox. Refer to the following table to avoid unnecessary adjustment:
to be adjusted:
Input shaft
Page 35-
13
Output shaft
(S1 and S2)
Page 35-42

Differential
Page 39-25

Parts Gearbox housing x x x
renewed:
Clutch housing x x x
Input shaft x
Output shaft (final drive) x
Differential housing x
Input shaft taper roller
bearing
x
Output shaft taper roller
bearing
x
Differential taper roller
bearing
x
Bearing support x

39-25




Adjusting differentiaI
The differential must be adjusted, when


Gearbox housing



Clutch housing



Differential housing

or the


Differential taper roller bearing

have been renewed.
Adjustment overview Page 39-24 .

- Pressing taper roller bearing outer race with oil
deflector ring into the clutch housing using
thrust piece 2050 Page 39-14 .

Note:
Inner and outer taper roller bearing races are a
pair. Do not interchange.


- Pressing taper roller bearing outer race without
shim into the gearbox housing using thrust
piece 2050 Page 39-16 .
- Fit differential into clutch housing


39-26




- Fit gearbox housing and tighten 5 bolts to
torque setting.



- Mount D.T.I. and "0" with 1 mm preload.
- Move differential up and down and recall play
indicated on D.T.I. (Example: 0.70 mm)
A - 60 mm gauge extension
Note:
Do not turn differential when measuring
otherwise the bearing will settle and a false
measurement will be given.
Determining shim thickness
The specified bearing preload is obtained by
adding a constant figure (0.40 mm) to the
reading obtained.
ExampIe:
Reading 0.70 mm
+ Preload (constant figure) 0.40 mm
Thickness of shim = 1.10 mm


39-27





- Remove gearbox housing and pull taper
roller bearing outer race out from gearbox
housing.
- Insert shims of correct thickness, thickest
shim first.
The following shims are available:
Size (mm) Part No.
0.65
0.70
0.75
02G 409 210
02G 409 210 A
02G 409 210 B
0.80
0.85
0.90
02G 409 210 C
02G 409 210 D
02G 409 210 E
0.95
1.00
1.05
02G 409 210 F
02G 409 210 G
02G 409 210 H
1.10
1.15
1.20
02G 409 210 J
02G 409 210 K
02G 409 210 L
1.25
1.30
1.35
1.40
02G 409 210 M
02G 409 210 N
02G 409 210 P
02G 409 210 Q
0.70+0.75 = 1.45
0.75+0.75 = 1.50
0.75+0.80 = 1.55
02G 409 210 A + B
02G 409 210 B + B
02G 409 210 B + C


39-28




-
Press outer race in again and tighten
gearbox housing to torque setting.



Checking friction moment
A - Commercial torque gauge 0 ... 600 Ncm
B - Extension for 1/2 " square drive socket
- Lubricate taper roller bearing with gear oil.
Friction moment:

New taper roller bearings 120 ... 320 Ncm

Used taper roller bearings at least 30 Ncm.